A container-packing system includes container-packing unit configured to facilitate loading of articles in a container at a loading station. The container-packing system further includes an article conveyor configured to transport articles to the loading station and a container conveyor configured to transport an empty container to and away from the loading station. The container-packing unit is located at the loading station and is configured to facilitate filling of the container with the articles.
Legal claims defining the scope of protection, as filed with the USPTO.
. A container-packing system, comprising:
. The container-packing system of, wherein the container-guide system includes a first clamp coupled to a first side of the foundation and a second clamp coupled to an opposite, second side of the foundation, and the first and second clamps are configured to engage the container when the container reaches the loading station.
. The container-packing system of, wherein the container-guide system further includes a first linear actuator coupled to the first clamp and a second linear actuator coupled to the second clamp, and the first and second linear actuators are configured to move the first and second clamps between a retracted position spaced a first distance from one another prior to the container reaching the loading station, and an extended position spaced a second distance from one another less than the first distance when the container reaches the loading station to exert a compressive force on the container prior to activating the agitator and filling the container with the articles.
. The container-packing system of, wherein first and second linear actuators each include a threaded piston coupled with the first clamp and the second clamp, respectively, so that the first clamp and the second claim can be moved toward or away from one another in the extended position and the retracted position.
. The container packing system of, wherein the container-guide system further includes a third linear actuator coupled to the first clamp and a fourth linear actuator coupled to the second clamp, and the third and fourth linear actuators are spaced apart from the first and second linear actuators and are configured to move the first and second clamps between the retracted position and the extended position with the first and second linear actuators.
. The container-packing system of, wherein the packing-unit conveyor includes a conveyor belt, a conveyor actuator configured to drive the conveyor belt, and plurality of rollers coupled to the foundation and underlying a portion of the conveyor belt to locate the conveyor belt between the portion of the plurality of rollers and the container.
. The container-packing system of, wherein the conveyor belt is a first conveyor belt and the plurality of rollers is a first plurality of rollers, and wherein the packing-unit conveyor includes a second conveyor belt spaced apart from the first conveyor belt and a second plurality of rollers coupled to the foundation and spaced apart from the first plurality of rollers.
. The container-packing system of, wherein the conveyor actuator includes a conveyor motor coupled to the foundation, a first actuator roller coupled to the conveyor motor and to the first conveyor belt to move the first conveyor belt relative to the first plurality of rollers, and a second actuator roller coupled to the conveyor motor and the second conveyor belt to move the second conveyor belt relative to the second plurality of rollers.
. The container-packing system of, wherein the conveyor motor is coupled to the foundation between the first and second actuator rollers, the first and second conveyor belts, and the first and second plurality of rollers.
. The container-packing system of, wherein the conveyor actuator further includes a gearbox coupled between the conveyor motor and the first actuator roller and between the conveyor motor and the second actuator roller, and the gearbox is configured to rotate the first and second actuator rollers in the same direction and at the same time to drive the first and second conveyor belts at the same rate.
. The container-packing system of, wherein the agitator includes an agitator motor and at least one eccentric weight coupled to the agitator motor and configured to impart vibrations on the foundation when activated.
. The container packing system of, wherein the foundation includes a foundation base configured to rest on the surface, a container support spaced apart from the foundation base and configured to support the container above the surface, and a suspension system interconnecting the foundation base and the container support.
. The container packing system of, wherein the suspension system includes a plurality of spring guides and a plurality of springs located in internal spaces defined at least partially by the plurality of spring guides.
. The container packing system of, wherein each of the plurality of spring guides includes a foundation-base guide coupled to the foundation base and a container-support guide coupled to the container support, and each of the plurality of springs is surrounded by at least one of the foundation-base guide and the container-support guide.
. The container packing system of, wherein the foundation-base guide includes a first guide post and the container-support guide includes a cylindrical tube surrounding a spring included in the plurality of springs.
. The container packing system of, wherein the spring surrounds the first guide post to locate the spring radially between the first guide post and the cylindrical tube, the container-support guide further includes a second guide post, and the spring surrounds the second guide post to locate the spring radially between the second guide post and the cylindrical tube.
. The container packing system of, wherein the container support includes a support plate coupled to the packing-unit conveyor, a first side wall coupled to a first lateral end of the support plate and extending in an upward direction away from the support plate, and a second side wall coupled to a second lateral end of the support plate and extending in the upward direction away from the support plate.
. The container packing system of, wherein the container-guide system includes a first clamp coupled to the first side wall and a second clamp coupled to the second side wall, and the first and second clamps are configured to engage the container when the container reaches the loading station.
. The container packing system of, wherein the first and second clamps are movable between a retracted position spaced a first distance from the first and second side walls, respectively, and an extended position spaced a second distance greater than the first distance from the first and second side walls, respectively.
. The container packing system of, wherein the first and second side walls are spaced apart from one another by a distance within a range of about 40 inches to about 46 inches and the first and second clamps are spaced apart from the support plate by a distance of at least 6 inches.
. A container packing unit comprising:
Complete technical specification and implementation details from the patent document.
This application claims priority under 35 U.S.C. § 119 (e) to U.S. Provisional Patent Application No. 63/662,616, filed Jun. 21, 2024, which is expressly incorporated by reference herein in its entirety.
The present disclosure relates to packaging, and particularly to packing containers. More particularly, the present disclosure relates to a system for packing a container with articles.
According to the present disclosure, a container-packing system includes container-packing unit configured to facilitate loading of articles in a container at a loading station. The container-packing system further includes an article conveyor configured to transport articles to the loading station and a container conveyor configured to transport an empty container to the loading station and a loaded container away from the loading station.
In illustrative embodiments, the container-packing unit is located at the loading station and is configured to facilitate filling of the container with the articles. The container packing unit includes a foundation, an agitator, and a motion control system. The foundation is configured to rest on a surface to support the container above the surface at the loading station. The agitator is coupled to the foundation and is configured to impart vibrations on at least a portion of the foundation and the container as the container is filled with the articles to cause the articles to settle within the container prior to the container leaving the loading station. The motion-control system is coupled to the foundation and is configured to control movement of the container relative to the foundation before and after activation of the agitator.
In illustrative embodiments, the motion-control system includes a container-guide system and a packing-unit conveyor. The container-guide system is configured to engage the container at the loading station to block movement of the container relative to the foundation while the agitator is activated and the container is filled with the articles. The packing-unit conveyor is configured to transfer the container to and from the loading station across the foundation.
Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived.
A container-packing system, in accordance with the present disclosure, includes a container-packing unitconfigured to facilitate loading of articlesin a containerat a loading stationand then transfer the containerin a downstream directionafter the containeris filled with the articlesas shown in. As the articlesare loaded in the containerat the loading station, the container-packing unitis configured to agitate the containerso that the articlessettle therein. As a result, empty space within the containeris minimized and more articlesare able to be packed in each containerat the loading station.
The container-packing systemfurther includes an article conveyorand a container conveyeras shown in. The article conveyoris configured to transport the articlesto the loading station. The container conveyorincludes a first conveyor segmentconfigured to transport the containerto the loading stationand a second conveyor segmentconfigured to transport the containeraway from the loading stationafter being filled with the articles. In some embodiments, the articlesare configured to be stacked or nested with one another in the containerand may include caps, lids, cups, bins, tubs, or any other article that is nestable with one another for storage and transportation. In other embodiments, the articles do not nest with one another in the container.
The container-packing unitis located at the loading stationand cooperates with the article conveyorand the container conveyorto fill the containerwith articlesand then transport the filled containerin the downstream direction. The container-packing unitincludes a foundation, an agitator, and a motion-control system. The foundationis configured to rest on a surface to support the containerabove the surface. The foundationis located in-line with the first conveyor segmentand the second conveyor segmentof the container conveyor. The agitatoris coupled to the foundation. The agitatoris configured to induce movement the foundationand the containeras the containeris filled with the articlesto cause the articlesto settle within the containerprior to the containerleaving the loading stationwith the second conveyor segment. The motion-control systemis coupled to the foundationand is configured to control movement of the containerrelative to the foundationbefore and after activation of the agitator.
The motion-control systemincludes a container-guide system, a packing-unit conveyor, and a control system. The container-guide systemis configured to engage the containerat the loading stationto block or restrict movement of the containerrelative to the foundation. When the container-guide systemengages the container, the containerremains on the packing-unit conveyorand moves with the foundationwhile the agitatoris activated and the containeris filled with the articles. The packing-unit conveyoris configured to transfer the empty containerfrom the first conveyor segmentof the container conveyorto the loading stationon the foundationin the downstream direction. Once the containeris filled with articles, the packing-unit conveyoris configured to transfer the filled containerfrom the loading stationon the foundationto the second conveyor segmentin the downstream direction. The control systemcontrols operation of the container-guide system, the packing-unit conveyorand the agitatorto control filling and transportation of the containerwith the articles. In some embodiments, the control systemmay also control operation of the article conveyorand the container conveyor.
The container-guide systemincludes a first clampcoupled to a first side of the foundationand a second clampcoupled to an opposite, second side of the foundation. The first and second clamps,are configured to engage the containerwhen the containerreaches the loading station. In this way, the clamps,block movement of the containerrelative to the foundationas the agitatormoves the foundationand the containerwith the foundationand the containeris filled with articles.
The container-guide systemfurther includes a pair of first linear actuatorscoupled to the first clampand a pair of second linear actuatorscoupled to the second clamp. The first and second linear actuators,are configured to move the first and second clamps,between a retracted position and an extended position. In the retracted position, the first and second clamps,are spaced a first distance from one another prior to the containerreaching the loading station. In the extended position, the first and second clamps,are spaced a second distance from one another less than the first distance. The actuators,are configured to move to the clamps,to the extended position after the containerreaches the loading stationto exert a compressive force on the containerprior to the agitatoractivating and the containerbeing filled with the articles. In some embodiments, the actuators,are omitted and the clamps,are biased toward one another to the extended position by one or more springs, for example, and the springs provide the compressive force on the containerat the loading station. An upstream end of each clamp,includes a tapered segment,to guide the containerbetween the clamps,as the containermoves in the downstream directionto the loading station.
The first and second actuators,are operated by pneumatics (i.e. air or another gas) and include a piston,that extends in response to a force (i.e. positive or negative pressure) applied to the piston,. Each piston,is coupled with the first clampand the second clamp, respectively, so that the first clampand the second clampcan be moved toward or away from one another in the extended position and the retracted position. In the illustrative embodiment, each piston,is also threaded so that the clamps,can be adjusted relative to the pistons,to a desired distance from one another in one or both of the extended position or the retracted position.
The packing-unit conveyorincludes first and second conveyor belts,, a conveyor actuatorconfigured to drive the conveyor belts,, and first and second plurality of rollers,coupled to the foundation. The first and second conveyor belts,are configured to move along the foundationin the downstream direction. The conveyor actuatoris configured to drive each of the conveyor belts,in unison with one another. The plurality of rollers,are oriented transversely to the downstream directionto allow movement of the containerand the conveyor belts,in the downstream direction.
The conveyor belts,form a loop around the first and second plurality of rollers,, respectively. The first and second plurality of rollers,underlie a portion of each conveyor belt,to locate portion of the conveyor belts,between the plurality of rollers,and the container. In some embodiments, the packing-unit conveyormay include only one conveyor belt and only one plurality of rollers as opposed to two separate, spaced apart conveyor belts,and sets of rollers,.
The conveyor actuatorincludes a conveyor motorcoupled to the foundation, a first actuator rollercoupled to the conveyor motorand to the first conveyor beltto move the first conveyor beltrelative to the first plurality of rollers, and a second actuator rollercoupled to the conveyor motorand the second conveyor beltto move the second conveyor beltrelative to the second plurality of rollers. The conveyor motoris coupled to the foundationbetween the first and second actuator rollers,, the first and second conveyor belts,, and the first and second plurality of rollers,.
The conveyor actuatorfurther includes a gearboxcoupled between the conveyor motorand the first actuator rollerand between the conveyor motorand the second actuator roller. The gearboxis configured to rotate the first and second actuator rollers,in the same direction and at the same time to drive the first and second conveyor belts,in the same direction and at the same rate.
The agitatorincludes an agitator motorand a pair of eccentric weights,coupled to the agitator motorand driven in rotation by the agitator motor. The agitator motorrotates the weights about an axis to impart vibrations on the foundationwhen activated.
The foundationincludes a foundation baseconfigured to rest on a surface, a container supportspaced apart from the foundation baseand, and a suspension systeminterconnecting the foundation baseand the container support. The foundation basesupports the container supportand the suspension systemabove the surface that the foundation baserests on. The container supportis configured to support the containerabove the surface. The suspension systemallows movement of the container supportrelative to the foundation basewhile the agitatoris activated.
The suspension systemincludes a plurality of spring guidesand a plurality of springslocated in internal spaces defined at least partially by the plurality of spring guides. Each of the plurality of spring guidesincludes a foundation-base guidecoupled to the foundation baseand a container-support guidecoupled to the container support. Each of the plurality of springsis surrounded by at least one of the foundation-base guideand the container-support guide.
Each foundation-base guideis a first guide post and the container-support guideincludes a cylindrical tubesurrounding one of the springs included in the plurality of springs. Each springsurrounds one of the first guide poststo locate the springradially between the first guide postand a corresponding cylindrical tube. Each container-support guidefurther includes a second guide post. Each springalso surrounds the second guide postto locate the springradially between the second guide postand the cylindrical tube.
The suspension systemmay further include one or more flexible tiesinterconnecting the container supportand the foundation baseas shown in. The flexible tiesblock separation of the container supportaway from the foundation basepast a predetermined amount, but allow movement of the container supporttoward the foundation baseas the springscompress while the agitatoris activated. The flexible tiesmay be removable from one or both of the container supportand the foundation baseto allow separation of the container supportfrom the foundation basefor service.
The container supportincludes a support platecoupled to the packing-unit conveyor, a first side wallcoupled to a first lateral end of the support plate, and a second side wallcoupled to a second lateral end of the support plate. The support platesupports the packing-unit conveyorrelative to the rest of the foundation. The first and second side walls,extend in an upward direction away from the support plateand support the first and second clamps,, respectively, above the support plate.
The container supportis preferably sized to support a standard size pallet having a length of 48 inches, a width of 40-42 inches and a height of 6 inches. The container supportmay be sized to support non-standard size pallets or other container support structures. The first and second side walls,are spaced apart from one another by a distancewithin a range of about 40 inches to about 46 inches. The first and second clamps,are spaced apart from the support plateby a distanceof at least 6 inches. In this way, a standard size pallet is able to fit between the first and second side walls,and pass below the first and second clamps,so that the clamps,engage the containerin the extended position.
The foundationfurther includes an actuator support bracketcoupled to the container supportand configured to support the conveyor actuatoron the container supportas shown in. The actuator support bracketincludes a base paneland a pair of side panels,coupled to opposite ends of the base panel. The actuator motoris fixed to the base panel. The side panels,extend upwardly from the base paneland are attached to the first and second side walls,, respectively. The conveyor actuator rollers,are simply supported between the gearboxand the first and second side panels,, respectively.
The conveyor actuatormay further include first and second pairs of guide rollers,as shown in. Each pair of guide rollers,is positioned below each respective plurality of rollers,with one of the guide rollers,on each side of each respective actuator roller,. The guide rollers,engage and guide each conveyor belt,toward each respective conveyor roller,.
The control systemis configured to control operation of each component included in the motion-control system(and other components in the systemsuch as conveyorsand). The control systemincludes one or more processors and memory storing instructions that, when executed by the one or more processors cause each component to operate in a container-loading sequence or method to load the containerwith articlesand transport the containeraway from the loading station.
Once the empty containerreaches the container-packing unit, the packing-unit conveyoris activated by the control systemto transfer the empty containerfrom the first conveyor segmentin the downstream directionto the loading stationdirectly on top of the container support. The control systemdeactivates the packing-unit conveyorwhile the containeris filled with the articles.
The control systemthen actuates the first and second actuators,to move the first and second clamps,from the retracted position to the extended position engaged with the container. Filling of the containerwith articles may begin before the clamps,engage the containeror after.
As the articlesare loaded into the container, the control systemactivates the agitatorto impart vibrations on the containerto cause the articlesto settle within the container. The agitatormay be continuously activated as the articlesare loaded or may periodically activate at intervals as the articles are loaded. The clamps,engage the containerwhenever the agitatoris activated.
The control systemmay include one or more sensorsconfigured to monitor the amount of articlespresent in the containerthroughout the loading sequence. The sensorscan be one or more of an optical sensor, infrared sensor, weight scale, laser, etc. The control systemmay activate the agitatorwhen the amount of articlesin the containerreaches one or more predetermined levels. The control systemmay also adjust a vibration frequency of the agitatoras the containeris filled.
Once the containeris filled, the control systemreleases the clamps,and again activates the packing-unit conveyorto transfer the filled container in the downstream directionfrom the loading stationto the second conveyor segment. The second conveyor segmentthen transports the filled container elsewhere for further packing, storage, and/or transportation.
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December 25, 2025
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